EX auto tranny to manual swap

[tjs4x4]

Am intending to do a swap to a 5 speed. What parts do I HAVE to have NEW for this swap? I know that the clutch master and slave cylinders need to be new, flywheel, clutch... How long has it taken any of you to do this? What was the biggest hurdle?

Will any model 5 speed tranny fit the auto transfer case that I have? What are the model #'s for the different vehicles: IE:M5OD-R1 etc.....

 

[joescool2008]

The m5od fit in my truck just fine, I have a 94 ranger 4x4 4.0 and the driveshafts and everything were the same, however i left that auto blockoff plate between the motor and tranny on there and had to pull it back out because it was rubbing and making a awful noise along with not fully disengaging. The tranny needs to be the 4x4 model as well because it has a extension housing tthat is differant. I bought new flywheel, master, slave, clutch assembly new around $350, and the tranny and pedal bracket from a junkyard. One thing you will need to swap that isnt super straightforward is the pedal bracket. Obviously your adding a pedal so the shaft that holds the pedals needs swapped and you have to remove half your dash to do that. In my case at least. I'm not fully done swapping yet though. Im not sure if i needed the manual tranny blockoff plate for spacing or what. I used the same starter and im not sure if thats why im making a noise when i start it. Still investigating. I work like 70-80 hours a week so free time is scarce. Oh and if you can figure out the wiring for the neutral safety switch thats fine and if not, I just took the one off the auto tranny, put a nut on it and a bolt through the other side so it thinks its parked all the time and this allows me to start it. O|< kinda like that lol pushes that button in where the lever used to.

 

[tjs4x4]

I've been told to use a new starter for the manual transmission, not reuse the auto one cuz it doesn't work for the manual.
What is the auto blockoff plate?

 

[joescool2008]

Just the plate between the motor and tranny that blocks off holes so debris doesnt get in. Mine was labelled "auto" and i said hell it wont matter, but i guess it does lol.

 

[chilsam]

Plate

Just the plate between the motor and tranny that blocks off holes so debris doesnt get in. Mine was labelled "auto" and i said hell it wont matter, but i guess it does lol.

You can modify the auto to work I use a half moon file ,curve on 1 side flat on the other use the manual starter as a guide then grind that raised rib down on the pass side

 

[tjs4x4]

I think I'm just gonna get a new starter, as I am pretty much starting from scratch.

I found a manual tranny yesterday, some guy called me and said he had one in his garage stored for awhile. Said his son said it worked when pulled. Not sure how long its been stored. $50 for the tranny as it has nothing on it. Gonna need all new parts. Thinkin I should open the tranny and check it to make sure I'm not putting in a broken tranny.

Anyone know what a clutch pedal switch is and where I can find one? Is it necessary?

 

[joescool2008]

Mine came in my master cylinder box from perfection. (the switch). Btw i put in the new manual starter and it doesnt grind anymore and it will shift while running . yay! Wish I woulda thought about that before i pulled it like 3 times. Oh and it's a neutral safety switch which doesnt allow the starter to kick on unless it's pressed in. I just pulled the sensor out of the auto and put a nut on it and a bolt through the other side so the switch thinks its in neutral all the time. This really doesnt hurt unless the person who operates your vehicle doesnt know that. Oh and on that plate the only place that grinded on me was the raised spot which grinded against my flywheel.